CN1203988C - 弹性伸缩性复合片料及其制造方法 - Google Patents

弹性伸缩性复合片料及其制造方法 Download PDF

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CN1203988C
CN1203988C CNB011303433A CN01130343A CN1203988C CN 1203988 C CN1203988 C CN 1203988C CN B011303433 A CNB011303433 A CN B011303433A CN 01130343 A CN01130343 A CN 01130343A CN 1203988 C CN1203988 C CN 1203988C
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CN1348748A (zh
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小林利夫
合田裕树
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Unicharm Corp
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    • A61F13/00—Bandages or dressings; Absorbent pads
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Abstract

本发明能使含有热塑性合成纤维的弹性伸缩性复合片料变得柔软。将可弹性伸缩的第一纤维网(2)和热塑性合成纤维组成的可非弹性伸长的第二纤维网(3)在y方向间断地接合在一起。第二纤维网(3)的纤维(6)中，其与长度方向相垂直方向上的断面的高度h与宽度w之比h/w在0.5以下。

Description

弹性伸缩性复合片料及其制造方法
技术领域
本发明涉及一种弹性伸缩性复合片料及其制造方法。
背景技术
在日本特表平8-504693号公报中，公开了多层弹性板及其制造方法。该弹性板由橡胶弹性层和与之接合的非弹性纤维层形成，非弹性纤维层在接合部与接合部之间形成褶。非弹性纤维层由纺粘工艺或熔吹工艺的任何一种方法所得到的纤维形成。
在上述公知技术中，虽然利用熔吹工艺可以得到小于0.1dtex的细纤维，但是，要想把纤维的断面控制成一定形状是很困难的。因此，该工艺对于把如纤维的断面形状作成扁平来提高纤维表面光泽度的目的来说，是不合适的。另外，在该工艺中，由于喷出纤维的喷嘴的直径不能太大，所以，要提高每一个喷嘴的喷出量、增多单位时间的纤维生产量是非常困难的。该熔吹工艺的难点虽然可以通过纺粘工艺的使用得以消除，但是，在纺粘工艺中，要想高效率地得到1dtex以下的细纤维，也是很困难的。此外，要想由此得到纤度小的纤维方面所特有的柔软的肌肤触感的纤维层非常困难。
发明目的
因此，本发明的目的是，解决由可弹性伸缩层和可非弹性伸长的纤维层组成的复合片料方面的在上述公知技术出现的制造上的难点。
技术方案
本发明的为了解决上述问题的第一手段是，提供一种弹性伸缩性复合片料，第二手段是提供一种制造该复合片料的方法。
在上述第一手段中，作为本发明的对象的复合片料，通过下述方式形成：将具有相互垂直的x方向和y方向，并且至少在上述y方向上可弹性伸缩的第一纤维网和由许多热塑性合成纤维组成的、在上述y方向上可非弹性伸长的第二纤维网，在上述y方向间断地接合，上述合成纤维在与上述第一纤维网接合的相互邻接的部位与部位之间的上述合成纤维的长度大于上述部位与部位之间的直线距离，该复合片料可在上述y方向弹性伸缩。
这种复合片料，作为本发明的特征是，上述合成纤维，在垂直于其长度方向的方向上的断面具有宽度w和与该宽度w垂直的高度h，上述高度h与上述宽度w之比h/w在0.5以下。所述第二纤维网包括不被分割的复合纤维的部分，所述热塑性合成纤维从所述复合纤维分割，所述复合纤维包括可分割成所述热塑性合成纤维的至少2种热塑性合成树脂；所述不被分割的复合纤维的部分，在所述接合的部位与所述第一纤维网接合。
上述第二手段是，作为本发明对象的复合片料的制造方法，该复合片料通过下述方式形成：将具有相互垂直的x方向和y方向，并且至少在上述y方向上可弹性伸缩的第一纤维网和由许多热塑性合成纤维组成并可在上述y方向非弹性伸长的第二纤维网，在上述y方向间断地接合，上述合成纤维在与上述第一纤维网接合的相互邻接的部位与部位之间的上述合成纤维的长度大于上述部位与部位之间的直线距离，该复合片料可在上述y方向弹性伸缩。
上述制造方法作为本发明的特征是，该复合片料通过下述工序制造：
a.朝上述y方向连续供给上述第一纤维网的工序；
b.通过熔融纺丝法得到将由至少两种热可塑性合成树脂组成的、可分别分割为各上述树脂的多种复合纤维，把作为该复合纤维的集合体的纤维网向上述y方向连续供给的工序；
c.使上述第一纤维网与上述复合纤维的纤维网重合在一起，把这两种纤维网在上述y方向上间断地形成的接合部位处一体化而形成复合纤维网的工序；
d.在所述工序c中所述接合之后，以足够的应力使所述复合纤维网在所述y方向伸长，从所述复合纤维网分割出所述第二纤维网，而在与所述第一纤维网接合的部位不分割所述复合纤维的工序；
e.让上述伸长的复合纤维网收缩，得到上述复合片料的工序。
作为本发明的一个比较合适的实施形式，上述方法还包括下述工序。即是说，将处于伸长状态或收缩状态的任何一种状态下的复合纤维网朝上述y方向连续供给、从多个喷嘴对该复合纤维喷射高压柱状水流、使该复合钎维分割的工序。
有益技术效果
本发明的弹性伸缩性复合片料，由于形成该复合片料的可非弹性伸长的纤维层的纤维纤度比较小，而且，纤维的断面形状是高度h与宽度w之比h/w为0.5以下的扁平形，因此，复合片料很容易朝其厚度方向变形，显得更加柔软。这样的纤维层的纤维，含有分割的复合纤维，所以，很容易使纤度变小，也很容易把纤维的断面调整成所需要的形状。本发明的制造方法，由于使用了纤度大，可以由大直径喷嘴喷射的复合纤维，因而，与通过熔吹工艺得到复合片料的构成纤维的情况相比较，能提高一个喷嘴的单位时间的纤维生产量。
附图的简单说明
图1是复合片料的透视图。
图2是复合片料的局部示意图。
图3是由其(I)、(II)表示纤维粗径部与细径部的断面的示意图。
图4是实施形式一个例子的纤维断面图。
图5是复合片料的制造工艺图。
发明实施的形式
下文，参照附图说明本发明的弹性伸缩性复合片料及其制造方法的详细情况。
图1是由本发明方法得到的弹性伸缩性复合片料1的透视图。复合片料1适用于用作一次性使用的尿布或生理用卫生巾、一次性使用的医疗用长衫等一次性使用的穿带物品的透液性或不透液性表面材料，图示的例子具有下层2和上层3，这两层2、3在接合部4熔敷或粘接，被一体化。复合片料1是可朝相互垂直的x方向和y方向中的至少y方向并按照虚线所示那样的方式弹性伸缩的。图中只例示出了形成下层2与上层3的纤维5、6的一部分。
复合片料1的下层2是可朝y方向、最好是可在y方向与x方向弹性伸缩。该下层2由热塑性弹性体等弹性原材料构成的短纤维或长纤维、连续纤维等集合体这样的弹性原材料组成的薄膜等形成。在图示的下层2由纤维5组成的情况下，纤维5是彼此通过机械地络合或通过熔敷或粘接而交织在一起的无纺布，或者是织物。下层2在外力的作用下使复合片料1朝y方向伸长时可弹性地伸长，解除该外力时，复合片料1可收缩。
复合片料1的上层3是可朝向x方向、y方向中的至少y方向非弹性伸长的层。该上层3是在接合部4与4之间连续的热塑性合成树脂纤维6的集合体，该纤维6可以是短纤维、较好地是长纤维，最好是连续纤维。各个纤维6的相邻接合部4与4之间的长度大于该接合部4与4之间的直线距离，纤维6的整体形成不规则的曲线的同时，遍布下层2的整个上面。复合片料1朝y方向伸长时，纤维6以在接合部4与4之间朝y方向直线延伸的方式改变方向。如果复合片料1收缩，纤维6再次形成曲线。在图示的例子中，上层3在接合部4处与下层2熔敷，使多数纤维6在接合部4处失去其形状而薄膜化。
图2是使上层3为上进行观察时的复合片料1的局部平面图。在图2中，形成上层3的许多纤维6中的一个纤维6a，在接合部4近旁有纤度大的粗径部11，在稍稍离开接合部4的地方分支，形成多个细径部12。纤维6的另一个纤维6b，其粗径部11很短，在接合部4近旁分支出细径部12。纤维6中的再一个纤维6c，其粗径部11比较长，在远离接合部4的地方分支出细径部12。
图3的(I)、(II)是图2的纤维6a的I-I线，II-II线的断面图。图3(I)示出了纤维6a的粗径部11的断面。纤维6a是聚丙烯树脂与聚酯树脂组成的复合纤维，其粗径部11具有例如8dtex的纤度，聚丙烯树脂层17与聚酯树脂层18将纤维6a的圆周方向等分16等分，相互交错地并置着。图3的(II)是粗径部11的各树脂层17、18分割所产生的细径部12的断面图。细径部12具有朝水平方向延伸的宽度w和与该宽度w垂直的方向上的高度h，高度h相对与该宽度w之比h/w最好在0.5以下，从例示的8dtex的粗径部11可得到约0.5dtex的细径部12。
纤维6即使在粗径部11的直径比较大，通过在接合部4的近旁细分割，依然能得到更好的柔软的肌肤触感。另外，如果细径部12具有比h/w为0.5以下的扁平的断面，则宽度w很容易在成为水平的状态下在片料1的表面扩展。该细径部12特别是在片料1的厚度方向容易变形，从而可使复合片料1变得更柔软一些。该扁平的细径部12和具有与之相同的断面面积的断面基本为圆形的一般的纤维相比较，在高度h方向上很容易变形。另外，该细径部12对复合片料1赋予扁形纤维特有的光泽。
图4的(I)是与图3的纤维6不同形式的纤维6的粗径部11的断面图，图4的(II)～(V)示出了从粗径部11分割的细径部12的各个断面。圆形粗径部11在上下方向上被4等分，使聚丙烯树脂层17与聚酯树脂层18相互重合在一起。如果分割各树脂层17、18，就可产生图示的各种形状的细径部12。细径部12的断面形状为新月形或基本为三角形或基本为矩形等，具有宽度w与高度h，两者的比h/w在0.5以下。
图5是表示复合片料1制造工序的一个例子的示意图。在图中的左方并排设置有向右方行走的第一环状带31和第二环状带32，在各环状带31、32的上方，设置有第一挤压机33和第二挤压机34，各挤压机33、34分别具有朝向环状带31、32的宽度方向并置成一列的多个喷嘴37或38。第一、第二挤压机33、34的正下方设置有通过环状带31、32空吸用的管道31a、32a。
第一挤压机33的喷嘴37，在导管31a的空吸作用下，将热塑性弹性体组成的弹性伸缩性的多条第一连续纤维41喷到第一环状带31上。第一连续纤维41最好在第一环状带31上相互熔敷，成为呈现出无纺布形态的质地稳定的第一纤维网41a，并向第二环状带32行进。第二挤压机34的喷嘴38，在导管32a的空吸作用下，将至少两种类型的热塑性合成树脂组成的可非弹性伸长的多条复合纤维60作为连续纤维喷到第一纤维网41a的上面，形成复合纤维的纤维网60a。
相互重合的第一纤维网41a与复合纤维的纤维网60a，在加热的一对轧光机辊47之间行进，在图中的机械方向上间断地形成的接合部4(参照图1)的地方熔敷成一体化，形成复合纤维网55a。复合纤维网55a进一步朝机械方向行进，在由一对前方辊53和一对后方辊54形成的伸长工序56中，朝机械方向伸长所需要的倍率、最好是伸长40～300％的同时，最好在接合部4与4之间，在形成该复合纤维60的每根树脂上分割复合纤维60。由复合纤维60形成的纤维网60a，在该伸长工序56中非弹性伸长，成为第二纤维网52a。在伸长工序56中，后方辊54以较前方辊53更快的圆周速度旋转，使复合纤维网55a可以伸长。经过后方辊54出来的复合纤维网55a，在保持伸长的原状态下，或者在从该伸长释放以收缩到大致为伸长前的尺寸的状态下，载置在第三环状带65上，并朝水流处理工序62行进。在工序62中，从朝向复合纤维网55a的宽度方向并置成一列的多个喷嘴63向第二纤维网52a喷射高压柱状水流。喷射的水由位于第三环状带65下方的导管64吸引。在该处理工序62中，对还没有分割的复合纤维60进行分割。经过处理工序62出来的复合纤维网55a如果还处在伸长的状态，则通过收缩工序(图中未示)，再通过干燥工序(图中未示)，作为弹性伸缩性复合片料1被卷曲。
图示工序的第一纤维网41a和第二纤维网52a分别成为图1的下层2和上层3，复合纤维60成为纤维6。另外，复合纤维60的被分割的部分为纤维6的细径部12(参照图2)，未被分割的部分为纤维6的粗径部11。
在该制造工序中的伸长工序56和之后的让复合纤维网55a收缩的工序中，第一纤维网41a弹性伸长之后收缩。第二纤维网52a借助于复合纤维60的非弹性伸长，其伸长部分产生永久的变形，该永久变形在第一纤维网41a收缩时，在接合部4与4之间形成曲线状，成为细径部12或粗径部11。复合片料1在机械方向的图1的y方向上伸缩时，第一纤维网41a弹性伸缩，随之，第二纤维网52a的纤维6以在接合部4与4之间以形成为直线的方式朝y方向延伸，或以形成为曲线的方式收缩。
用于得到纤维6的复合纤维60，是将至少两种相溶性低的树脂相互组合在一起的。这种组合，除了例示的聚丙烯与聚酯外，还有聚丙烯与聚乙烯、聚丙烯与尼龙、聚酯与尼龙、聚酯与聚乙烯、聚乙烯与尼龙等。这种复合纤维60具有在纤维周面呈现出树脂被此的界面的断面形状，这样的复合纤维60，在工序56中伸长时，因树脂彼此的伸长特性的差异而使树脂彼此在相互的界面剥离，形成所谓的分割纤维。另外，复合纤维60通过此时喷射高压柱状水柱，也能使形成该复合纤维60的树脂彼此在其界面剥离，形成分割纤维。这样得到的分割纤维就成为图2所示的纤维6的细径部12。在复合纤维网55a在工序56中伸长时、充分地分割复合纤维60的场合，对于复合纤维网55a来说，也可以省去之后的水流处理工序62。此外，在本发明中，在使复合纤维60伸长的工序56中，分割复合纤维60的工序也可以成为水流处理工序62那样的工序。这样的复合纤维60可使用纤度为20dtex以下、分割为2以上的复合纤维。复合纤维60的单位面积重量最好是2～100g/m2。
本发明的制造方法，由于通过伸长工序56的伸长和之后的高压柱状水流的分割，经过两个阶段使复合纤维60变小，因此，可以制作出纤度特别小的例如0.05dtex程度的非常细的细径部12。细径部12的断面形状可通过复合纤维60纺丝时喷嘴38的形状来控制。本发明的复合片料1及其制造方法，也可以通过在下层2的下面设置与上层3同样的可非弹性伸长的纤维层的形式，即在第一纤维网41a的上下两面接合有形状相同或形状不同的第二纤维网52a的形式来实施。

Claims (6)

1.一种复合片料，通过下述方式形成：将具有相互垂直的x方向和y方向，并且至少在上述y方向上可弹性伸缩的第一纤维网和由多种热塑性合成纤维组成的、在上述y方向上可非弹性伸长的第二纤维网，在上述y方向间断地接合，上述合成纤维在与上述第一纤维网接合的相互邻接的部位与部位之间的上述合成纤维的长度大于上述部位与部位之间的直线距离，该复合片料可在上述y方向弹性伸缩，其特征是：
上述合成纤维，在垂直于其长度方向的方向上的断面具有宽度w和与上述宽度w垂直的高度h，上述高度h与上述宽度w之比h/w在0.5以下；
所述第二纤维网包括不被分割的复合纤维的部分，所述热塑性合成纤维从所述复合纤维分割，所述复合纤维包括可分割成所述热塑性合成纤维的至少2种热塑性合成树脂；
所述不被分割的复合纤维的部分，在所述接合的部位与所述第一纤维网接合。
2.根据权利要求1记载的复合片料，其特征是，上述合成纤维的断面形状为矩形，上述矩形的宽度与高度分别是上述宽度w和高度h。
3.根据权利要求1记载的复合片料，其特征是，上述合成纤维的断面形状为三角形，上述三角形的底边与高分别是上述宽度w和高度h。
4.一种复合片料的制造方法，该复合片料通过下述方式形成：将具有相互垂直的x方向和y方向，并且至少在上述y方向上可弹性伸缩的第一纤维网和由多种热塑性合成纤维组成并在上述y方向可非弹性伸长的第二纤维网，在上述y方向间断地接合，上述合成纤维在与上述第一纤维网接合的相互邻接的部位与部位之间的上述合成纤维的长度大于上述部位与部位之间的直线距离，该复合片料可在上述y方向弹性伸缩，其特征是，该复合片料通过下述工序制造：
a.朝上述y方向连续供给上述第一纤维网的工序；
b.通过熔融纺丝法得到将由至少两种热塑性合成树脂组成的、可分别分割为各上述树脂的多种复合纤维，把作为该复合纤维的集合体的纤维网向上述y方向连续供给的工序；
c.将上述第一纤维网与上述复合纤维的纤维网重合，把该两种纤维网在上述y方向上间断地形成的接合部位处一体化、形成复合纤维网的工序；
d.在所述工序c中所述接合之后，以足够的应力使所述复合纤维网在所述y方向伸长，从所述复合纤维网分割出所述第二纤维网，而在与所述第一纤维网接合的部位不分割所述复合纤维的工序；
e.让上述伸长的复合纤维网收缩，得到上述复合片料的工序。
5.根据权利要求4记载的方法，其特征是，还包括将处于伸长状态或收缩状态的任何一种状态下的上述复合纤维网朝上述y方向连续供给、从多个喷嘴对该复合纤维喷射高压柱状水流、使该复合纤维分割的工序。
6.根据权利要求5记载的方法，其特征是，在上述使复合纤维网伸长的工序及向上述复合纤维喷射高压柱状水流的工序的任何一个工序中得到的分割纤维，其垂直于该分割纤维的长度方向的方向上的断面形状具有宽度w和高度h，上述高度h与宽度w之比h/w在0.5以下。
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